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First KZ project…. 1980 KZ1000 06 Dec 2016 20:24 #749709

  • spdygon
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I clear all the threaded holes with a tap and use a wire wheel on the threaded bolts
1982 GS1000sz Katana ( #15...17K Miles)
1982 GS1000sz Katana ( # 297....7100k Miles)
1978 Kz1000 Z1R. 10K Miles1
1978 kz1000 z1r 27k miles
1977 KZ 1000 A ( Project ) 54K Miles
1976 Kz900A4 (Red)21K miles
1976 Kz900A4 ( Red)7500 miles
1974 Z1 900 project

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First KZ project…. 1980 KZ1000 01 Jan 2017 12:24 #751085

  • JOE MKII
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Cleaned the top case , cleaned all the threads, cleaned and visually inspected the tranny i got off e-bay. Looks good, I will run through the checks outlined in the manual for clearances and such. The gears and dogs look great, the gears are nice and tight when engaged so don't expect it will be out of tolerance.
Cleaned all the bearings and oiled them , very smooth and quiet operation.
Hoping to button it up in the next week or so depending on my work load,

The cases where the output shaft rides that was scarred up I polished lightly with 1500 grit to smooth it out put the hearing from the new tranny in place and shined a light to see if there were any gaps. looked really good, so no major damaged that I can see to the cases that would cause problems.
I may use a tiny drop of bearing retainer on both sides of the cases when assembling to ensure a good fit….
Do you guys think thats a good idea??
Anything I should know thats not in the manual or obvious that I should be aware of?



I believe its called "Oppositional Defiance Disorder"

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First KZ project…. 1980 KZ1000 01 Jan 2017 13:02 #751091

  • SWest
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Looks good to me. B)
Steve

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First KZ project…. 1980 KZ1000 02 Jan 2017 05:22 #751148

  • rrsmsw9999
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Follow the manual and you will be fine. BTW I have only seen a couple of instances of worn KZ tranny gears. Usually, if broken, it's shift forks or the bearings. Also if your model has the Kaw neutral finder you will not be able to hand shift to second or above and set the drum correctly before assembly. Good luck. R
1980 KZ 1000E2
Crashed 6/2016

1980 KZ550A
Sold 3/2016

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First KZ project…. 1980 KZ1000 02 Jan 2017 11:32 #751168

  • JOE MKII
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All the other parts, forks, shift rods, ECT are in good shape. It all seems pretty straight forward at this point.
Looking forward to getting this done and moving on to other parts of this refresh project,

I did receive some new in the package clutch springs wit the tranny, they are labeled for kx125, I have not measured them yet.
Is tis a common swap or a like for like replacement?
I believe its called "Oppositional Defiance Disorder"

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First KZ project…. 1980 KZ1000 02 Jan 2017 13:46 #751177

  • JOE MKII
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rrsmsw9999 wrote: . Also if your model has the Kaw neutral finder you will not be able to hand shift to second or above and set the drum correctly before assembly. Good luck. R


Does this mean there is no way to check engagement and run it through the gears while its on the bench?
I played around with it all afternoon checking and cleaning getting ready to button it up, but I see (I think I see) that it will not shift past neutral on the bench.

:unsure: Don't want to screw this up.
I have been reading and re reading the Kawasaki manual and the clymers manual but I feel a bit dyslexic at the moment.
I believe its called "Oppositional Defiance Disorder"

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First KZ project…. 1980 KZ1000 02 Jan 2017 16:35 #751197

  • JOE MKII
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From all the searches I did it seems you put the tranny in neutral place the drum and shift forks at neutral and hope for the best .... :blink:

The manual seems to assume this as did the posts I have read .

If this is incorrect PLEASE let me know :)

Thanks!!
I believe its called "Oppositional Defiance Disorder"

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First KZ project…. 1980 KZ1000 02 Jan 2017 17:18 #751209

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That's right.
Steve
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First KZ project…. 1980 KZ1000 03 Jan 2017 06:32 #751266

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Ditto on Steve, bot of your posts are right, you will not be able to shift to second and neutral position is correct. Also don't pull the shift shaft out by accident, you will drop the shift forks in the case, a minor problem if the case is bolted up :P Good luck, follow the manual. R
1980 KZ 1000E2
Crashed 6/2016

1980 KZ550A
Sold 3/2016
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First KZ project…. 1980 KZ1000 05 Jan 2017 09:55 #751463

  • JOE MKII
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Can anyone tell me if this looks like the proper amount of engagement depth on the dogs for a stock KZ tranny?
I have only worked on two other trannys and both were undercut by MRE and the engagement was a bit deeper than in theses pics.


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First KZ project…. 1980 KZ1000 05 Jan 2017 13:19 #751474

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What do the faces look like?
Steve

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First KZ project…. 1980 KZ1000 05 Jan 2017 17:01 #751500

  • JOE MKII
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They look good, it shows that it engaged like that before. The edges show some rounding but I don't know how to judge. All the wear marks are similar to the tranny I removed when looking at the rounding . The faces show the original tranny may have had better engagement.
What is significant as far as rounding and engagement?? Seems I would need to see a few more to get comfortable....
My guess is I'm over thinking it :silly:
I believe its called "Oppositional Defiance Disorder"

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